( Reaffirmed 2004 ) IS : 9647 - 1986 Indian Standard GENERAL REQUIREMENTS AND METHODS OF TESTS FOR LOW FREQUENCY CONNECTORS BELOW 3 MHz INCLUDING DC ( First Revision ) Connector for Electronic In the Chair DRK.M.MATHUR Members Equipment Sectional Committee, Representing Electrotechnology LTDC 16 Hindustan Pvt Ltd, Bangalore SHRI C. R. RANGANATHAN ( Alternate to Dr K. M. Mathur ) SHRI R. ADINARAYANAN Ministry of Defence ( R & D ) SHRI K. N. BALASUBRAHMANYAN( Alternate ) SHRI BAKUL HARISHANKAR Allied Electronics Corporation, Bombay SHRI PRAD~P BAKUL ( Alternate ) MAJ-GEN N. DAYAL Development Electronics Trade & Technologv Corporation Ltd, New Delhi SHRI P. M. RAMACHANDRAN (Alternate ) SHRI S. C. DUGGAL National Airport Authority, New Delhi SHRI K. K. ICHHUPNANI ( Alternate ) DR R. R. DUTTA GUPTA Ministry of Defence ( DGI ) SHRI M. R. GO~;IA MC Gogia, Dist Thane JOINT DIREC.TOR STDS Research, Designs and Standards Organization, Lucknow ( S & T ) III JWNT DIRIXXOR STDS ( S & T ) ( Alternate ) Electronic Components Industries Association SHRI K. A. MATHEW ( ELCINA ), New Delhi LT-COL PAUL VARGHESE ( AItmate ) Hindustan Aeronautics Ltd, Hyderabad SHRI G. LINGA MURTHY SHRI K. SURYAPRASAD ( Alternate ) Indian Telephone Industries Ltd, Bangaloro SHRI P. V. RAO SHRI LAKSHMINARAYANA( Alternate ) Hyderabad Connectronics Ltd. Medak SHRI P. N. REDDY SHRI S. V. KABADE ( Alternate ) Gilard Electronics Pvt Ltd, Ko ta SHRI c. S. SETH1 SNRI K. S. SETHI ( Alternate) Telec;mgmication Research Centre, New SHRI R. N. SHARMA i: . SHRI SOMNATW MAITY( Alternate ) ( Continued @ Copyright 1557 on page 2 ) BUREAU OF INDIAN STANDARDS This publication is protected ui.der the Indian Copyright Act (XIV of 1957 ) and reproduction in whole or in part by any means except with written permissionof the publisher sh;:ll be deemed to be an infringement of copyright under the said Act. IS : 9647 - 1986 ( Continued from page 1 ) Members SRINIVASAW SHRI MLJRARILAL ( Alternate ) SHRI RAM SWARVP Representing Bharat Electronics Ltd, Bangalore Laboratory ( CSIR ), New Natio;;$fhysicai SHRIMATIBRINDA O/E/N Connectors Ltd, Co&in SHRI M. SVKUMARAN ( Alternate ) Amphetronix Ltd, Pune LT-COL PAUL VARGHESE SHRI S. VASUDEYAN ( Alternate ) Director General, BIS ( Ex-oficio Member ) SHRI N. SRINIVASAN, Director ( Electronics ) SHRI P. GEORGE VARGHESE Secretary SHRI NARENDRA S~NGH Assistant Director ( Electronics ), BIS SHRI 0. N. KHANNA ( Alternate > Panel for Low Frequency Connectors for Electronic LTDC 16: P2 Equipment, Ministry of Defence ( R & D ) SHRI R. ADINARAYANAN Department of Electronics, New Delhi SHRI P. N. GLJPTA Allied Electronics Corporation, Bombay SHRI BAKUL HARISHANKAR SHRI P. N. REDDY Hyderabad Connectronics Ltd, Medak SHRI S. V. KABADE ( Alternate ) LT-COL PAUL VARDHESE Amphetronix Ltd, Pune SHRI S. VASUDEVAN( Alternate ) O/E/N Connectors Ltd, Cochin SHRI P. GEQRGE VARGHESE 2 IS : 9647 - 1986 Indian Standard GENERAL REQUIREMENTS AND METHODS OF TESTS FOR LOW FREQUENCY CONNECTORS BELOW 3 MHz INCLUDING DC ( First Revision ) 0. FOREWORD 0.1This Indian Standard ( First Revision ) was adopted by the Indian Standards Institution on 3 December 1986, after the draft finalized by the Connectors ,for Electronic Equipment Sectional Committee had been approved by the Electronics and Telecommunication Division Council. 0.2 This standard covers general requirements and methods of test for low frequency connectors for use in electronics and telecommunication equipment for dc and frequencies below 3 MHz. The Indian Standard covering requirements and methods of tests for radio connectors for use in electronics and telecommunication equipment for frequencies above 3 MHz is being prepared separately. 0.2.1 To cover fully the requirements of various types of low frequency connectors, this standard would be supplemented by sectional and detail specifications. The sectional specifications would cover the common requirements of each type of low frequency connectors as given below: a) Printed circuit connectors. b) Rank and panel connectors, and c) Circular connectors and others. The detai!Ed requirements of connectors belonging to any of the above-mentioned types would be covered in the individual detail specifications. 0.3 This standard was originally published in 1980 keeping in view the experience gained in the use of IS : 3826 ( Part 1 )-1966* and also the need to harmonize the requirements with the corresponding JSS and IEC standards on the subject. In view of the system of specification structures adopted to cover the requirements of low frequency connectors as outlined in 0.1 of IS : 3826 ( Part l )-1966* and IS : 3826 ( Part 2 )-197Ot *Connectors for frequencies below 3 MC/S: Part 1 General requirements and tests. tconnectors for frequencies below 3 MC/S: Part 2 Battery connectors for electronic equipment. 3 IS : 9647 - 1986 dealing with low frequency connectors below 3 MHz would be withdrawn on the availability of the standards in accordance with the new system. 0.4 This revision has been made to take into account the developments that have taken place at international level and elsewhere. Following tests from JSS 50800 General requirements for connectors dc and low frequency, issued by Ministry of Defence, have also been included in this revised standard: a) Magnetic permeability, b) Contact protection, c) Drop, d) Bending, e) Board insertion force ( over stress >, f) Frame strength, g) Altitude immersion, h) Ozone exposure, j) Fire-proofness, and k) Flammability. 0.5 The ob.ject of establishing this series of standards on connectors is to specify uniform requirements for judgin, 0 the mechanical, electrical and climatic properties as well as safety aspects of connectors to describe test methods and to specify_ the dimensions of such connectors for interthangeability and compatibility. 0.6 Some of the tests specified in this standard may not be required for certain applications and in such cases they need not be called for. Additional tests may be needed, if specified in the relevant specification. 0.7 While preparing this standard, assistance has been derived from the following publications: IEC Pub 130-I ( 1962 ) Connectors for ff-equencies below 3 MHz, the International Electrotechnical Commission. IEC Pub 130 1 A ( 1962 ) Supplement to Publication 130-l ( 1962) Connectors for frequencies below 3 MHz, the International Electrotechnical Commission. JSS 50800 Gcreral requirements for connectors dc and low frequency, Directorate of Standardization, Ministry of Defence. 0.8 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, 4 IS : 9647- 1986 expressing the result of a test, shall be rounded off in accordance with IS : z-1900*. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard. 1. SCOPE 1.1 This standard covers the general requirements and methods of tests for judging the electrical, mechanical and climatic properties of low frequency connectors intended for use in electronic and telecommunication equipment, for frequencies up to 3 MHz, etc. 1.2 This standard does not cover the following types of connectors: a) Those which are exclusively intended for the connection of mains supply voltage to an equipment; and b) Those which are essentially designed for use at frequencies above 3 MHz. 2. TERMINOLOGY 2.1 For the purpose of this standard, the following terms and definitions, in addition to those given in IS : 1885 ( Part 40 )-1974?, shall apply. 2.2 Type Tests - Tests carried out to prove conformity with the requirements of this specification. These are intended to check the general qualities and design of a given type of connector. 2.3 Acceptance, Tests - Tests carried out on samples selected from a lot for the acceptance of lot. 2.3.1 Lot - All connectors of the same type, category and rating manufactured by the same factory during the same period using the same process and materials. 2.4 Routine requirements Tests - Test carried out on each connector which are likely to vary during production. to check the 3. CATEGORIES 3.1 The connectors covered by this standard are classified into climatic categories in accordance with the general rules given in IS : 9000 (Part 1 )-1977f. *Rules for rounding off numerical values ( revised ). tElectrotechnica1 vocabulary: Part 40 Connectors. Part 1 General. $Basic environmental testing procedures for electronic and electrical items? 5 IS : 9647 - 1986 3.2 The severities for the cold, dry heat and damp heat, and steady state tests for the connectors covered by this standard should preferably be within the following ranges: - 65 to - 10°C Lower category temperature Upper category temperature + 70 to + 200°C Damp heat ( steady state ) 04 to 56 days values selected within these ranges shall be chosen IS : 9000 ( Part 1 )-1977". from those listed in 4. MATERIALS AND WORKMANSHIP 4.1 Materials - The connectors shall be constructed from the most suitable materials which shall be free from flaws and shall conform to relevant Indian Standard Specifications, if any. All materials used in the construction of the connectors shall be such as are not susceptible to any mutual chemical reaction over the entire range of temperature and humidity for which the connectors are designed. 4.2 Workmanship - All parts of the connectors shall be manufactured and processed in a careful and workman like manner in accordance with the good engineering practice. 5. ELECTRICAL RATINGS 5.1 Values of Rated Voltage - For each type of connector, the values Standard of rated voltage shall be specified in the relevant specification. values from which the individual ratings should preferably be chosen are 34, 100, 354, 500 and 700 V; and 1, 1'6, 2'5, 4, 6'3, 10, 16 and 25 kV. NOTE - The values of 34 V and 354 V are given as they are included Safety regulations. in existing 5.1.1 The values of the rated voltage are dc. 6. MARKING 6.1 Unless otherwise specified, each connector shall have the following information clearly and indelibly marked on it: a) Type designation in accordance with the relevant specification, b) Manufacturer's name or trade-mark, as indicated c) Identification on contacts specification, *Basic environmental Part 1 General. testing proceduers for electronic by the relevant and electrical items: 6 IS : 9647 - 1986 and the customer, and 4 Country of manufacturer. 6.1.1 Each connector may also be marked with the Standard Mark. NOTE -The use of the Standard Mark is governed by the provisions of the Bureau of Indian Standards Act, 1986 and the Rules and Regulations made thereunder. The Standard Mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of that standard under a well-defined system of inspection, testing and quality control which is devised and supervised by BIS and operated by the producer. Standard marked products are also continuously checked by BIS for Details of conditions under conformity to that standard as a further safeguard. which a licence for the use of the Standard Mark may be granted to manufacturers or producers, may be obtained from the Bureau of Indian Standards. d) Any other mark as agreed to between the manufacturer 7. CLASSIFICATION OF TESTS 7.1 Type Tests - The sequence of type tests and number of samples for The each test shall be specified in the relevant detail specification. samples shall be selected at random, preferably from regular production. 7.2 Routine Tests - The routine tests shall be carried out as specified in. the relevant detail specification. 7.2.1 If during the routine tests more than 10 percent of the lot fails,. the entire lot may be rejected. 7.3 Acceptance Tests - The acceptance tests shall be carried out as specified in the relevant detail specification. Two groups of samples ( Group A and Group B ) shall be selected, preferably at random from the lot that has passed routine tests. 8. GENERAL CONDITIONS FOR TESTS 8.1 General - The tests shall be carried out on the connectors in the condition received from the manufacturer or the supplier. In no case shall the contact parts be cleaned or otherwise prepared prior to the tests, unless explicitly so agreed. 8.2 Standard Atmospheric Conditions for Testing - Unless otherwise specified, all tests shall be carried out under standard atmospheric conditions for testing specified in IS : 9000 ( Part 1 )-1977*. 8.3 Pre-conditioning - Before measurements are made the connectors shall be stored at the measuring temperature and the relative humidity for a time sufficient to allow the entire connector to reach these conditions. The recovery period called for, after conditioning, is adequate for this purpose. 8.4 Correction to be Applied - When measurements are made at an ambient temperature other than the reference temperature, the result *Basic environmental testing procedures for electronic and electrical items: Part 1 General. 7 IS : 9647 - 1986 shall, where necessary, be corrected to the reference temperature. The ambient temperature and the relative humidity during the test shall be stated in the test report. 8.5 Drying - Where drying before measurement is required, it shall be done in accordance with 4.5 of IS : 9000 ( Part 1 )-1977*. 8.6 Mounting - When mounting is specified in,a test, the connector shall be rigidly mounted on a metal plate using a clamp for free connectors or the normal fixing for fixed connectors. The dimensions of the mounting plate shall be such that the contour of the specimen is exceeded [ see IS : 9001 ( Part 12 j-1977? 1. 8.7 Other Precautions be exposed to draughts, cause errors. During measurements the connectors shall not direct sun-rays and other influences likely to 8.8 Accuracy of Test Equipment - The accuracy of test equipment shall be specified in the relevant test clause. 8.9 Probes - The use of sharp probes to make contact for testing purposes must be avoided. The test conditions shall simulate the normal engagement of the mating contacts. 8.10 Multicontacts - Where individual contact tests are specified and there are more than six contacts of the same rating, the number tested shall be not less than six, all the contacts in case of six or less number which shall be selected, where applicable, as having the least creepage distance between contacts or the metal housing, if any. Tests involving comparison shall be made on the contacts originally tested. 8.11 Approvrd Mating Components -Where an approved mating component is specified for engagement with the component under test, the dimensions of the mating component shall conform to the requirements of the appropriate drawings. When testing printed circuit connectors, for mating sets rtad appropriate connectors and printed boards ( or gauges ). 8.12 Sizing acd Test Gauges - The sizing and test gauges shall be as specified in the relevant detail specification. 9. VISUAL EXAMINATION 9.1 The cor.nectors and 9.1.2. Part 1 General. shall be visually examined for conformity and of with 9.1.1 items: and * Basic environmental testing procedures t Guidance for environmental eetrical items for dynamic tests. testing: Tar electronic Part 12 Mounting electrical electronic 8 IS : 9647 - 1986 shall be in accordance with 6. 9.1.2 The workmanship, finish and assembly shall be satisfactory. number of the contacts, if any, shall be as specified. 9.2 There shall be no deterioration in the features ( mentioned and 9.1.2 ) after electrical, mechanical and climatic tests. 10. DIMENSIONS 10.1 The dimensions AND MASS 9.1.1 Markings The in 9.1.1 of the connectors shall be checked and shall comply with those specified in the relevant specifications for connectors. Any suitable method may be used, except that the gauges should be used where specified by the relevant specification. 10.2 The mass of a minimum of six connectors shall be checked and shall comply with those specified in the relevant specifications for connectors. 11. CLEARANCE 11.1 Clearance AND CREEPAGE DISTANCES and creepage distance shall be checked when specified by the relevant specification. A guide for these values is given in Appendix A. 12. ELECTRICAL TESTS 12.1 Contact Resistance 12.1.1 General Measuring Requirements - The contact resistance may be measured either with direct current or alternating current. In case of dispute, the dc `measurement shall govern. The contact resistance shall normally be calculated from the potential difference measured between the points intended for connection of the wiring. The contact shall be made before the measuring voltage is applied. In order to prevent the breakdown of insulating films on the contacts the emf of the measuring circuit shall not exceed 20 mV dc or ac peak. In order to prevent the undue heating of the contacts, the current flowing shall not exceed one ampere of the value specified in the relevant detail specification. For ac measurements the frequency shall be 1 kHz f 200 Hz. The measuring apparatus shall be such as to ensure an accuracy of i_ 10 percent. For each type of connector there are the following two series of measurements: a) determination of mean value of contact resistance of the contacts of mated sets of connectors ( RI >, and b) determination of mean value of the contact resistance of the individual resilient contacts ( & ). Measurements (a) and (b) shall not be carried out on the same item. 9 IS :9647 -1986 12.1.2 Measuring Cycle - For measurement with dc, one measuring cycle shall consist of: a) making the contact, b) connection of the voltage source, 4 measurement with current flowing in one direction, 4 measurement with current flowing in opposite direction, disconnection of voltage source, and breaking the contact, e> f> For measurement with ac, one measuring cycle shall consist of: a) making the contact, b) connection of the voltage source, c) measurement d) disconnection of voltage source, and e) breaking the contact. Measuring cycles shall be carried out in immediate succession. 12.1.3 Measurements on Muted Sets - The number of contacts to be measured and the value of contact resistance shall be specified in the relevant detail specification. 12.1.4 Measurements on Individual Contacts ( Resilient Contacts Only ) - Prior to the measurements of contact resistance, the following sizing procedure shall be carried out: a) Socket contacts shall have a maximum size pin gauge inserted and withdrawn five times, and b) Pin contacts shall be inserted in a minimum size socket gauge and withdrawn five times. The measurement on the individual contacts shall be carried out as follows: a) Socket contacts with a minimum size pin gauge inserted, and b) Pin contacts inserted in a maximum size socket gauge. All necessary details of the gauges and the number of contacts to be There shall be measured shall be specified in the relevant specification. five measuring cycles. The average of the values per contact thus obtained is the resistance of the contact under test ( R,). The value of any individual measurement shall not exceed twice this value. 12.1.5 Measurement of contact resistance may be repeated at a specified highest value of current, if required by the relevant detail specification. 10 IS:9647-1986 12.1.6 For measurement of contact resistance at low current and at millivolt range, modifications of the measuring method or special requirements or both may be specified by the relevant detail specification. Typical examples of methods of measurements are given in Appendix B. 12.1.7 Requirements - The value of the contact resistance shall not exceed the value specified in the relevant specification. Preferred values for the upper limit of the contact resistance to be quoted in the relevant specification are 3 and 10 milli ohms. NOTE 1 -Any indicated deviation in the test report. from the specified procedure shall be normally NOTE 2 - For low current contacts for use in the microvolt tions of the measuring method or special requirements or both in the relevant detail specification ( see Appendix B ). range, modificamay be specified 12.2 Variation of Contact Resistance 12.2.1 The variation of the contact resistance of mated sets of connectors shall be determined during the vibration test. 12.2.2 The measurement of the contact resistance shall be made throughout the whole of the test frequency sweep in each direction during the vibration test (see 14.13 ). The variation of contact resistance shall be determined by means of a cathode-ray oscilloscope ( with a long persistance screen ) displaying the potential difference between the points intended for the connection of wiring to the contacts with a direct current of 10 5 2 mA passed through the contact, the emf of the measuring circuit shall not exceed 20 mV. The number of contacts to be tested and the severity of the vibration test shall be specified in the relevant specification. 12.2.3 The tieasuring apparatus shall: a) have a frequency characteristic which is substantially flat between 400 and 1 000 Hz with a decay below and above of approximately 3 dB at 70 Hz and above 3 dB at 5 000 Hz, b) be such as to ensure a measuring accuracy better than f20 percent, and c) be calibrated with a sinusoidal voltage at 1 kHz. 12.2.4 Requirements - The value of the voltages produced by variation of contact resistance shall not exceed the value specified in the relevant detail specification. 12.3 Screen Continuity 12.3.1 Connectors having metallic covers, intended to provide continuous screening when mated, shall be tested for screen continuity. Measurement shall be made on mated sets of connectors. Free connectors 11 IS : 9647 - 1986 shall be fitted with short lengths of appropriate cable. The resis.tance shall be measured through all joints in series as follows: a) Between cable screens for free connectors; b) From cable screen to panel mounting shell, where one of the connectors is a fixed type, and c) Between panel mounting shells, where both connectors are fixed. 12.3.2 The measurements shall be made in a dc circuit having an emf not exceeding 2'5 V and a current not exceeding 1 A. The measuring The apparatus shall be such as to ensure an accuracy of f 10 percent. value of resistance shall not exceed the value specified in the relevant specification. 12.4 Insulation Resistance 12.4.1 The connectors shall be mounted as specified in 8.6. The insulation resistance shall be measured with a dc voltage of 100 f 15 V or 500 + 50 V as specified by the relevant detail specification. The insulation resistance shall be measured after an electrification time of 1 minute rt 5 seconds. NOTE -Where appropriate, the reading may be taken after a shorter period. 12.4.2 The measurement shall be made between each contact, in turn, and the mounting plate; all other contacts being connected to the mounting place. The value of the insulation resistance shall be not less than the value specified in the relevant detail specification. Unlessotherwise specified, the measurement error at the insulation resistance value required shall not exceed IO percent. NOTE - When insulation resistance measurements are made before and after a test, both measurements shall be made under the same conditions, including use of same polarity as the initial measurement. 12.5 Voltage Proof 12.5.1 A test voltage ( see 12.5.2 ) shall be applied between any contact, and all other contacts and outer metal parts of the connector together. The voltage shall be steadily increased to the specified value at a rate of approximately 500 V ( rms or dc `) per second, unless otherThe test voltage shall be maintained for a period of. wise specified. 1 minute for type tests and 5 seconds for acceptance tests, unless otherwise specified. When required, suitable current limiting device shall be used to limit current surges to the values specified. Upon completion of the test, the voltage shall be gradually reduced to avoid voltage surges. 12.5.2 The magnitude and nature of test voltage shall be specified the relevant detail specification. 12.5.3 There shall be no breakdown or flash over. 12 in, IS :9647 - 1986 12.6Corona ( Discharge ) 12.6.1 For this test, the appropriate cable shall be attached to the connector and the test voltage shall be applied between the conductors of the cable. The connectors shall be tested both mated and unmated. The voltage to be applied shall have a frequency between 40 and 60 Hz and it shall be increased gradually until discharge occurs. In order to determine the `extinction voltage' the test voltage sha!l be decreased gradually until no discharge occurs and the value of the voltage shall be noted. The total duration of the application of the voltage shall not exceed five minutes. The voltage shall be not less than the value specified in the relevant specification. 12.6.2 The measuring circuit for this test shall be as described Fig. 1 and 12.6.1 or a circuit giving the same results. TO BE CONNECTED ACCORDANCE WITH 1 in IN 12.6.1 i----o\ "- -1 OSClLLOSCOPE FIG. 1 CIRCUIT ARRANGEMENT FOR CORONA TEST 12.6.2.1 The frequency of parallel resonance for the circuit formed by the inductance of the choke coil, and all capacitance ( such as cable capacitance to earth, input capacitance of the cathode-ray tube and capacitance of connecting wires to earth ) shall be between 0'1 and 1 MHz and at this frequency the impedance of the circuit measured from the. input termination of the oscilloscope shall be not less than 0'1 MQ. The resistance of the choke coil shall be sufficiently low so as to avoid interference from 40 to 60 Hz signal at maximum sensitivity of the cathode-ray tube. The oscilloscope shall have such a sensitivity at the frequency range up to 1 MHz that it is possible to clearly distinguish corona voltages of 50 V and its input impedance shall be not less than 1 MQ 13 IS : 9647 - 1986 12.7 Noise - Under consideration. 12.8 Temperature Rise 12.8.1 The test shall be performed on mated pairs of connectors, with the contacts assembled in the connectors. The contacts shall be wired using suitable stranded copper wire of the same rating as the contacts. For 4 contact connectors, all contacts shall be connected in series. For 6 contact connectors, the three phase contacts shall be connected in series with the three neutral contacts connected in parallel. All jumpers are to be at least 61 cm long. Thermocouples shall be used to monitor the temperature of the contact terminals. Rated dc current shall be applied through the contacts for a of each termination shall be minimum of 4 hours. The temperature measured to determine compliance with requirements after the 4 hours of loading. 12.8.2 The temperature rise of the individual contact terminals shall There shall be no not be more than 30°C above ambient temperature. evidence of physical damage. 12.9 Ground Resistance 12.9.1 The socket shall be mounted by its normal mounting a copper plate of 6'35 mm minimum thickness. With a plug mated to the socket, a resistance measurement shall be made cable clamp screw on the plug to the copper plate, using ohmmeter of the four terminal type. 12.9.2 The resistance shall not exceed 250 milliohms. 12.10 Arc Rupture 12.10.1 Connectors, less coupling ring, shall be subjected to 50 continuous cycles of engagement and disengagement while carrying a 50 percent electrical overload of their rated current. The cycling procedures and electrical load shall be as follows: a) Engagement and Disengagement: 1) The socket shall be firmly mounted. The plug shall be mounted on a reciprocating ( cycling ) mechanism and axially aligned with the socket. 2) The cycling mechanism shall mate the socket and plug to their normal mating depth. At the initiation of testing and each subsequent cycle, the connector pair shall be mated, and remain mated for a period of `5 second minimum. The connector pair shall then be separated at a rate of 25 cm f 25 mm per second. After separation the connectors shall be remated at the same speed. One mating and unmating 14 means to property from a a milli- IS : 9647 - 1986 sequence is considered 1 cycle. The mating and unmating cycle shall be conducted at a rate not exceeding 6 complete cycles per minute. b) Electrical Load: 1) The socket shall be connected to a 400 cycles source, and the pins to an electrical load. 2) The voltage shall be applied between 1 phase contact and 1 neutral contact in the 4 contact connector; and 1 phase contact and 2 neutral contacts ( in parallel ) in the 6 contacts connector. 3) A steady state inductive load equal to 150 percent of rated current, at a power factor between 0`75 and 0'80, and at a minimum of 208 volts rms, shall be applied using the circuit shown in Fig. 2. A shunt resistance in parallel with the APPLIED LINE VOLTAGE GROUND FUSE R, - &I - Shunt resistance 1 100 [ ;F - PF +- Power factor Closed circuit line volts I - Current Lb - Inductive load FIG. 2 TYPICAL CIRCUIT FOR ARC RUPTURE E- PP - 15 IS : 9647 1986 inductance is permissible, provided the current through the resistor does not exceed 1 percent of the total load current. The inductance shall not alter the waveform of the power supply * 12.10.2 There shall be neither electrical nor mechanical damage which would prevent the connectors from being fully mated and unmated by hand. Flexible spring members of contacts shall not weld together. Contacts shall maintain shape and there shall not be any excessive vaporization of metal or contact distortion as a result of arc rupture tests. 12.11 Magnetic Permeability - The permeability of the assembled connectors shall be measured by a suitable apparatus. Requirements for this test shall be given in the relevant detail spec?fication. 13. MECHANICAL TESTS ON CONTACTS AND TERMINATIONS 13.1 Probe Damage and Restricted Entry Tests ( Female Contacts Only )- The object is to verify that the elastic system ensuring contact will not be subject to deterioration in cases of insertion of test probe. 13.1.1 The female contact shall be embedded in the connector insert and locked to prevent its rotation in the insert during test. 13.1.2 Probe Damage Test - A test pin, of dimensions specified in 13.1.4 is inserted into the female contact to a depth of 3/4 A ( see Fig. 3 ). The axis of the female contact is kept horizontal during the test. The test pin is held by a test device enabling a constant bending moment to be applied to the female contact. With this device free and unsupported, the connector is rotated slowly through 360" about its longitudinal axis in such a way that the force is applied uniformly over the entire internal surface of the female contact with the extremity of the test pin. This operation is repeated with the test pin inserted to a depth l/2 A and then to a depth l/4 A (see Fig. 3 ). The contact shall withstand the bending movement applied without any evidence of visible damage. After this test, the female contact shall fulfil the gauge retention force requirements specified in 13.2. When this test is required by the detail specification, the following detail shall be specified: 4 Dimension A - Minimum depth of female contact bore measured from the hard face of the insert, b) Shape and dimensions of the test pin, d Value of the moment to be applied, and 4 Any deviation from the test method. 16 IS:9647- 1986 13.1.3 An example of the test device is illustrated in Fig. 3. 13.1.4 The test pin shall conform to the following requirements: 4 The diameter shall be equal to the maximum b) 4 diameter of the actual pin of the connector increased by 0'13 mm for actual pin diameter greater than 0'89 mm and by 0'076 mm for actual pin diameters less than 0'89 mm; The pin shall have a spherical end; and It shall be made of hardened steel and shall have a polished surface. INSERT INSULATING MATER,lAL , . I TEST PIN SOCKET CONTACT Nom I - A = Depth from front end of female contact of female contact bore, excluding curvature at the bottom. insert face to bottom NOTE 2 - Spacers of suitable length and profile may be fitted over the test pin to achieve the specified depth of penetration into the female contact during the second and third tests. FIG. 3 CROSSSECTION OF TESTPIN INSERTION 13.1.5 Restricted Entry Test - This test is limited to female contacts classed as restricted entry types. The object of this test is to verify that a specified oversize pin cannot be inserted into the female contact. A test gauge consisting of a `no-go' pin of dimensions specified in the detail specification shall be inserted so that the test pin is brought in the centre and parallel to the axis of the contact. The axial force required to insert. 17 IS : 9647 - `1986 the gauge into the contact shall be specified in the relevant specification. The specified oversize pin cannot be inserted into the female contact. The number of contacts to be checked shall be specified in the relevant specification. The oversize pin shall have a spherical end and shall be made of hardened steel. The force to be applied shall be specified in the relevant specification. 13.2 Gauge Retention Force ( Resilient Socket Contacts ) 13.2.1 This test shall be carried out on the individual resilient socket contacts by using gauges as specified in the relevant detail specification. 13.2.2 The contact shall first have a maximum size gauge inserted and withdrawn three times. A minimum size gauge shall then be inserted in the contact and the contact shall support the weight of the gauge in a vertical downwards position. The details of the gauges, including weight of the minimum gauge, shall be specified in the relevant specification. 13.3 Maintenance Ageing ( for Removable Contacts Only ) 13.3.1 All contacts shall be removed and reinserted once, using an appropriate tool conforming to the requirements of the relevant detail specification. Counterpart connectors shall be mated and unmated once and the force shall be as specified. A minimum of 20 percent, but not less than 3 contacts, shall be removed and reinserted nine more times, using an appropriate tool conforming to the requirements of the relevant detail specification. The contact insertion and remova. forces shall bmeasured in accordance with 13.4 during the first and ninth cycles on half, but on not less than three, of the contacts selected for this test. After the tenth insertion of the contacts, the force to mate and unmate the counterpart connector shall be measured as specified in 13.5. 13.3.2 All removable ing to the requirements 13.4 Contact Only ) Insertion contact connectors of 13.4 and 13.5. and Removal Force shall be capable ( for Removable of conformContacts 13.4.1 Contacts shall be inserted and removed from the corresponding connector inserts by means of a tool conforming to requirements of the relevant detail specification and procedures, and with instrumentation capable of measuring the force applied parallel to the axis of the contacts. The test shall be performed on the first and ninth cycles of the maintenance aging procedure ( see 13.3 ). 13.4.2 The axial forces required to insert and remove removable contacts shall be as spe'cified in the relevant detail specification. 13.5 Contact Engagement and Separation Force 43.5.1 Sockets shall be mounted in a suitable position or fixture .applyicg gradually increasing loads for the engagement and separation 18 for of .S : 9647 - 1986 test pins from the sockets. Test pins shall be as specified. Insertion of test pins shall be to a depth of 3'55 mm minimum when measured from The test pin shall not bottom in the the front of the socket contact. socket. Performing this test in the sequence set forth below, measurements shall conform to the requirements of contact engagement and separation forces: a) Insert and separate a maximum diameter pin in and from each socket contact, then insert and remove a minimum diameter pin in the same sockets. During insertion and separation of the minimum diameter test pin, the forces shall conform to the minimum specified. b) Insert and separate a maximum diameter pin in and from each socket contact three times. During the third cycle the engagement and separation forces shall not exceed the maximum specified. 13.5.2 The contact engagement and separation forces shall be specified in the relevant detail specification. 13.6 Torque 13.6.1 With the sleeve of the plug held rigid, a twisting force of 0'226 Nm shall be applied for at least one minute to the tip of the plug assembly in a direction tending to loosen the tip of the plug. On three-element plugs having a dead collar between the tip and the ring, a twisting force of 0'17 Nm shall also be applied to the dead collar, in a direction tending to loosen it from the assembly. 13.6.2 The torque applied between the separate metal parts of the plug finger shall cause no damage to, or loosening of, any parts thereof. 13.7 Contact Pin Strength 13.7.1 Removable contacts shall be mounted in a suitable fixture and a load applied to the pin as shown in Fig. 4. The rate of trave! of the testing machine shall not exceed 25 mm per minute, and a force of 9& 0'28 N shall be maintained for one minute. The permanent set shall be the difference between the initial and final position of the point of load application after load removal. 13.7.2 Unless otherwise specified, no permanent set more than 0'127 mm shall be allowed. 13.8 Contact Depression 13.8.1 A plate shall be applied to the contacts of the connectors with non-rigid contacts in such a manner that the normal plane of the contacts is depressed to a distance of 3'5 mm from the front edge of the shell. After completion of the test, The depressive force shall be measured. contact resistance shall be measured. 19 IS : 9647 - 1986 PERMANENT L u FULL Mating End Size 2"o 22 All dimensions FIG. 13.8.2 4 in millimetres. ENGAGEMENT LENGTH Load Moment 0% 0.036 CONTACT STRENGTH TEST 113'5 N. value. The force required to depress the contacts shall not exceed There shall be no change in contact resistance from initial 13.9 Cover Chain Tensile Strength 13.9.1 The protective cover shall be securely held and a tensile static load of 10'25 kg shall be applied to the end of the chain for 5 minutes in each direction as follows: a) With the axis of the chain at right angles to the axis of the holding fastener, and b) With the axis of the chain in the same axis as that of the fastener. 13.9.2 Protective without damage. 13.10 Resistance covers with chains shall withstand the tensile test to Solvents 13.10.1 The connectors shall be subjected to the resistance to solvent test in accordance with the procedure laid down in IS : 9000 ( Part 20 )1979*. The marked portion of the connector shall be brushed. *Basic environmental testing procedures for electronic and electrical part 20 Resistance to clearing solvents and permanence of markings. 20 items: IS : 9647 - 1986 13.10.2 The marked portion should not come out or be pealed off. 13.11 Resistance to Soldering Heat 13.11.1 The connectors shall be tested to the resistance to soldering heat in accordance with the procedure laid down in IS : 9000 ( Part 18/ Set 2)- 1981*. 13.112 Each termination come out. 13.12 Compatibility 13.12.1 The compatibility shall be applied. gauges specified in the relevant specification shall be checked and no termination should 1312.2 The gauge shall be accepted without the application of undue force. Where `GO-ON-GO' gauges are specified, the `GO' gauge only shall be accepted. 13.13 Polarizatixr 13.13.1 Polarizing Device - The specified gauge shall be applied, where no gauge is specified, an appropriate mating connector shall be used. The polarising device shall engage before any other mating parts make contact. 13.13.2 Mismating - Attempts shall be made to mismate the connectors with their appropriate mating items using a force/torque not greater than that specified. It shall not be possible to mate the connectors in any other than the correct sense. 13.13.3 Orientation - Where a contact assembly is capable of being oriented in relation to its shell in more than one position, attempts shall be made to mate or make contact between all possible orientations in the same shell size. It shall not be possible to mate or make contact between poles or start the coupling device between different orientations in the same shell size. 13.14 Soldering - Connector terminations shall be subjected to a solder bath test in accordance with IS : 9000 ( Part lS/Sec 1 )-1981t. The period of recovery after immersion of terminations in solder bath shall be -specified in the relevant specification. There shall be no sign of deterioration and terminations shall get wet easily. *Basic environmental Part 18 Solderability test; `yBasic environmental Part 18 Solderability test, testing procedures for electronic and electrical items: Section 2 Resistance of items to soldering heat. testing procedures for electronic and electrical items: Section 1 Solderability of wire and tag terminations. 21 Is : 964T - 191 13.15 Robwtness of Terminations 13.15.1 Tensile Test - This test shall be carried out, in accordance with IS : 9000 ( Part 19/Set 1 )-1978*. There shall be no sign of fracture, loosening' of parts movements relative to the body of the connector or any other mechanical failure. The weight of the load and duration of the test shall be specified in the relevant specification. l&l??.2 Bendilig Test - This test shall be applied to,all terminations in accordance with IS : 9000 ( Part 19/Set 3 )-1978* for two bends or as specified in the relevant detail specification. There shall be no sign of fracture, loosening of parts, movements relative to the body of the connector or any other meohanicalz failure. 13.16 Contact Protection 13.1'6.X The front edge of the shell of the plug connector shall be scooped within' the front aperture made by the shell of the mating sockets. The front edges of both shells shall be in contact during this test. X3.%2 Long Shell ConneetomConnectors designed to provide protection in, sockets or plugs equippedi with make contacts shall not permit the edge of the shell of the mating' plugs or sockets to touch the male contacts. 13.16.3 Short SJ~ell connectors - Csnneckms designed to provide protection only in sockets equipped %ith male contacts shall note permit the edge of the shell of the mating plug to touch the male contacts. 14. MECHANICAL TESTS ON COMPLETE CONNECTORS 14.1 Insertion an& Witidrawal Force 34.1.Z This test shall. be oa@iedx out on mated sets of oonnectors. The force necessary to separate and, thaa necessary to fully engage a set of connectors, shall: be applied gradually anda measured. These~measurernents shall be carried out five times in succession. The withdrawal force an6 insertion force shall each be taken as the average of a series of five consecutive measurerneri~. Nom 1 - In cases where insertion and witHdrWa1 forces are not specified quantitat'ively, the reletint dktdl specifkatibn shall indicate tile method of applic&ion.of NOTE insertion and' withdratib for example; dY hand or bY sPecfa!'tool. 2 - A gauge may be u&d to stirWlate one-Of the tnafing parts. *Basic enviionmental testing procedur& fi~6trel&titonic ahd,electr'ical' items: Part i9 Test for rob\lstnkss of termitiatioris an& ihte#a# tioufititig, dlevicelr; Section I Tensile test, and. S:Ctioti 3". Bendiog test. 33 IS : 9647 - 1986 14.1.2 The withdrawal force shall be within the limits specified in the The insertion force shall not exceed the relevant detail specification. values specified in the relevant detail specification. 14.2 Mechanical Strength ( for Free Conneators Only ) 14.2.1 The object of this test is to determine the suitability of a free connector for use under the most arduous conditions such as frequent dropping on hard surfaces and to check whether live parts become accessible under such conditions. 14.2.2 The mechanical strength of the connector shall be tested in a tumbling barrel ( see Fig. 5 ), the sample being allowed to fall from a The barrel is height of 500 mm on a steel plate of 3 mm thickness. turned at a rate of 5 rev/min, 10 falls per minute thus taking place. Only one sample shall be tested at a time. The total number of falls shall be specified in the relevant specification. 14.2.3 After the tests the connector shall not show any serious d,amage impairing its safety. No parts shall have become detached or loosened. Pin contacts shall not be deformed such that they no longer comply with the requirements for clearance and creepage distances. 14.3 Static Load ( for Fixed, Connectors. Only ) 14.3.1 The object of this test is to, determine the suitability of fixed connector for use in position which may be subject to transverse forces. All dimensionsin millimetres. FIG. 5 TUMBLING BARREL 23 IS :9647 - 1986 14.3.2 The connector shall be mounted as specified in 8.6. A steady force shall be applied to the outer shell of the connectors in a direction parallel to the mounting plane. Tbe value of the force and its point of application shall be as specified in the relevant specification. Continuity of the contacts shall be monitored during the test. The connector shall be removed, unmated and inspected to 3 times magnification for damage A typical example for carrying out the test is given in or breakage. Appendix C. 14.3.3 After this test, the connector shall be visually examined and there shall be no deterioration. 14.4 Contact Retention ( in Insert ) 14.4.1 Not more than two contacts on the connector need be tested, unless otherwise specified. The test contacts shall be as widely separated as possible. 14.4.2 The force, as specified in the relevant detail specification, shall be applied for a period of 10 seconds along the axes of the contacts being tested in both directions consecutively. The force shall be applied steadily. There shall be no permanent displacement of the contact in relation to its insert, unless otherwise specified, and no damage or loosening of parts. 14.5 Contact Retention ( Solder Contact Connectors ) 14.5.1 Axial loads shall be applied individually to five contacts ( or all contacts if the number is less than five ) in unmated connectors in the normal removal direction. The test contacts shall be a,s widely separated as possible. The load shall be as specified in the relevant sheet and shall be applied uniformly at a rate of 5 N per second. The contacts shall withstand the. specified load. 14.6 Contact Retention (Crimp Contact Connectors ) 14.6.1 Axial loads shall be applied individually to five contacts ( or all contacts if the number is less than five ) in unmated connectors in the normal removal direction. The test contacts shall be as widely separated as possible. The load shall be as specified in the relevant sheet and shall be applied uniformly at a rate of 5 N per second. 14.6.2 The same contacts shall then be withdrawn and inserted nine times using the applicable tools. The axial load test shall then be repeated as above. The contacts shall in both tests withstand the specified load. 14.7 Insert Retention (In Shell) 14.7.1 Cable fittings shall be removed. An axial force, as specified in the relevant detail specification, shall be applied to the insert on the .24 IS : 9647 - 1986 connector in both directions consecutively. The force shall be increased steadily at a rate of approximately 45 N per second, until the specified force is reached. 14.7.2 The insert shell. 14.8 Pull 14.8.1 The socket and plug shall be mated. The socket shall be mounted rigidly in a vertical plane. A device, such as a link or harness, shall be affixed to the plug which is below the socket. A dead weight of 18'16 kg is placed on the device. Repeat this test by adding 11'35 kg to a device secured to the cable. In each instance, the weight is abruptly placed on the device. 14.8.2 Connectors shall withstand axial pull of not less than 18'16 kg applied to the shell and 11'35 kg applied to the cable. The socket and plug shall lock and unlock without difficulty and there shall be no visible damage. 14.9 Bond Strength Body Assembly 14.9.1 The connectors shall be subjected to the bond strength test to determine adhesive separation force. When the insulated body of the connector is constructed of two or more parts, the connector shall be tested as follows using test fixture, such as shown in Fig. 6. assembly shall maintain its normal location in the FIG. 6 BOND STRENGTHTEST 25 TS:964?--1986 a) Secure lower half of the connector in a jig or fixture that is onethird of length o.f the connector, excluding the mounting; b) Support. the connector by its normal mounting means; and c) Gradually obtain a maximum applied force of 225 N perpendicular to the mating surface of the parts. 14.9.2 The connector shall show no evidence of cracking, breaking, loosening of parts or delamination of the assembly when a force of 4'5 N per position is applied. 14.10 Acceleration ( Steady State ) 14.1O.l~This test shall be carried out in accordance with IS : 9000 ( Part 9)-1984*. Unless otherwise specified, the connector should be mounted as specified in 8.6 with suitable cable using the normal Cable-to-cable connection may connecting. devices of the connector. be held to the jig by a suitable clamp on one half of the connector assembly. The loading current shall be 100 mA minimum. using During the test, the c0ntact.s should be monitored for interruptions suitable monitoring devices capable of detecting interruptions of one microsecond or longer. Unless otherwise specified, the electrical interruptions shall not exceed 1 microsecond. 14~0.2 The connector shall then be su.bjected to the fol!owing tests and shall meet the reqUireUNItS specified in the relevant detail specifications: a) Visual examination, b) Contact resistance, and c) Sealing. 14.11 Bump 14.11.1 This test shall be carried out in accordance with IS : 9000 ( Part 7/Set 2 )-1979*. Unless otherwise specified, the connector should be mounted as specified in 8.6 with suitable cable using the normal connecting as devices of the connector. Cable to cable connection may be held to the jig by a suitable clamp on one half of the connector assembly. The loading current shall be 100 mA minimum. During test, the contact shall be monitored for interruptions suitable monitoring devices capable of detecting interruptions *Basic environmental testing procedu Part 7 Impact test, Section 2 Bump. Part 9 Acceleration ( stead] state ) t 1st. `es for electronic and electrical using of one jt,,s: 26 Is :-9647 - l-986 microsecond interruptions Unless otherwise or longer. shall not exceed 1 microsecond. specified, the electrical 14.11.2 The connector shall then be subjected to the following test and shall meet the requirements specified in the relevant detail specification: a) Visual examination, b) Contact resistance, and c) Sealing. 14.12 Shock 14.12.1 The test shall be carried out in accordance with IS : 9000 ( Part 7/See 1 )-1979". Unless otherwise specified, the connector should be mounted as specified in 8.6 with suitable cable using the normal Cable-to-cable connection may be connecting device of the concector. held to the jig by a suitable clamp on one half of the connector assembly. The loading current shall be 100 mA minimum. During the test, the contact should be monitored for interruptions using suitable monitoring devices capable of detecting interruptions one microsecond or longer. Unless otherwise specified, the electrical interruptions shall not exceed 1 microsecond. 14.12.2 The connector shall then be subjected to the following test specified in the relevant detail and shall meet the requirements specification: a) Visual examination, b) Con?act resistance, and c) Sealing. 14.13 Vibration 14.13.1 This test shall be carried out in accordance with IS : SOCO ( Part 8 )-1981*. Unless otherwise specified, the connector should be mounted as specified in 8.6 with suitable cable using the normal Cable-to-cable connection may be connecting devices of the connector. held to the jig by a suitable clamp on one half of the-connector assembly. The loading current shall be 100 mA minimum. During the test, the contact shall be monitored by interruptions using suitable monitoring devices capable of detecting interrupticns of one microsecond or longer. Unless otherwise specified, the electrical interruptions shall not exceed 1 microsecond. *Basic environmental testing procedures Part 7 Impact test, Section 1 Shock. Part 8 Vibration ( sinusoidal ) test. 27 for electronic and electrical items: IS :9647 -1986 14.13.2 At the conclusion of this test, the connectors shall be subjected to the following tests and shall meet the requirements specified in the relevant detail specification: a) b) c) d) Visual examination, Dry circuit, Contact resistance, and Sealing. 14.14 Drop 14.14.1 The connector shall be dropped six times at random from a height of 1'8 m. The floor or barrier receiving the impact shall be 5'08 mm fir backed by a concrete or rigid steel frame. 14.14.2 The connectors shall then be subjected to following tests and shall meet the requirements specified in the relevant detail specification: a) b) c) d) e) Visual examination, Contact resistance, Voltage proof, Insulation resistance, and Sealing. 14.15Bending 14.15.1 The plug shall be inserted horizontally into a hole or set of holes, 11'12 mm deep in a steel plate not less than 16 mm thick. The diameter of each hole shall be equal to that of the aperture of the appropriate jack. A force of 36 N shall be applied for one minute at right angles to and not more than 12'7 mm from the card end of the plug body. After completion of the test the plug shall be checked for profile, size and concentricity by means of the gauges or any other suitable means. 14.15.2 There shall be no distortion tricity. 14.16 Board Insertion Force 14.16.1 Connectors shall be tested for high insertion force by inserting a test board as specified and applying a force of 225N in the direction of insertion. 14.16.2 There shall be no evidence of physical damage. 28 of dimensions, size and concen- IS : 9647 - 1986 14.17 Frame Strength 14.17.1 The jack shall be mounted on a suitable panel with the long axis of the jack horizontal and heads of the pile-up clamping screws facing upward. A load of 13'62 kg freely suspended between the pileup clamping screws shall be applied for 5 minutes. 14.17.2 There shall be no visible rapture of joint. 15. MECHANICAL TESTS ON CABLE FIXING AND CABLE ENTRY 15.0 The object of these tests is to determine: a) whether the cable entry is so shaped and finished that there is no risk of damage to the exterior of the cable ( see 15.1 ), and b) that the device for fixing or clamping the cable is adequate when forces in different directions are applied to the attached cable ( see 15.2, 15.3 and 15.4 ). 15.1 Effect of Cable Rotation 15.1.1 An appropriate cable shall be attached in the normal way to the connector. The length of the cabIe shall be specified in the relevant specification. The free end of the cable shall be made to describe a circle about the axis of the connector so that the angle between the cable and this axis is 45" to 50". During the test, the cable shall not rotate about its axis. The number of the revolutions shall be specified in the relevant detail specification. 15.1.2 After the test, the cable shall not show any sign of deterioration due to rubbing. 15.2 Effectiveness of Cable Clamping Device Against Cable Pulling 15.2.1 An appropriate cable shall be attached in the normal way to the connector, except that the conductors of the cable are not fixed to the contacts. The length of the cable to be attached shall be approximately 25 cm. A force is then applied to the free end of the cable parallel to the axis of the cable and perpendicular to the plane of the cable entry. The value of the force to be applied and duration of the application of the force shall be specified in the relevant detail specification. 15.2.2 After this test the cable shall not have been displaced by more than 2 mm in relation to the clamping device. 15.3 Effectiveness of Cable Clamping Device Against Cable Bending 15.3.1 An appropriate cable shall be attached in the normal way to the connector. The length of the cable shall be specified in the relevant 29 IS :%47 - `1986 The assembled connector and cable is kept in a horizontal specification. position. A bending force is then applied by attaching weight at a specified distance from the plane of the cable entrance, as specified in The weight is then removed and the the relevant detail specification. cable is brought back to the original position. These operations are considered as to be one bend. The number of bends shall be specified in the reievant detail specification. 15.3.2 After the test, the cable shall not have moved in relation to the connector. 15.4 Effectiveness of Cable Clamping Devices Against Cable Torsion 15.41 Connectors shall be attached to both ends of an appropriate cable. The length of the cable shall be specified in the relevant detail specification. One of the connectors shall be fixed and a torque as specified in the relevant detail specification shall be applied to the other. 15.4.2 After the test, there shall be no slipping or rotation of the cable in relation to the connectors. 16. CLIMATIC TESTS 16.1 General - Prior to the climatic tests, the connectors shall be mated and unmated 20 times. Wherever applicable the connectors shall be mounted as specified in 8.6. For each test carried out on sets of connectors, half of the number of items shall be mated and half the number shall be unmated, unless otherwise specified. In each test the final measurements shall be carried out in the order stated. The connectors shall be pre-conditioned as specified in 8.3. 16.2 Climatic Sequence 16.2.1 Dry Heat 16.2.1.1 This test shall be carried out in accordance with IS : 9000 ( Part 3/Set 2 )-1977* using the appropriate degree of severity. The connectors shall be exposed to the specified temperature for a period of 16 hours. At the end of this period and while still at the high temperature, the insulation resistance shall be measured and shall not be less .than the value specified in the relevant detail specification. 16.2.1.2 The connectors shall then be removed from the chamber and exposed to the standard recovery conditions appropriate to this test, and after recovery, the connectors shall be visually examined. There shall be no visible damage. *Basic environmental testing procedures Part 3 Dry heat test, Section 2 Dry heat sudden change of temperature. for electronic test for non-heat and electrical items: dissipating items with 30 IS:9647 - l!W 16.2.2 Damp Heat, Accelerated ( First, Cycle ) 16.2.2.1 This test shall be carried out in accordance with 7.4 of IS : 9000 ( Part 5/Set 2 )-1981". The connectors shall be subjected to this test for `one cycle of 24 hours. 16.2.2.2 The connectors shall then be removed from the chamber and exposed to the standard recovery conditions appropriate to this test. After recovery, the connectors shall be visually examined. There shall be no visible damage. 16.2.3 Cold 16.2.3.1 This test shall be carried out in accordance (Part 2/Set 2 )-1977" using the appropriate degree of connectors shall be exposed to the specified temperature The connectors shall then be removed from the chamber the standard recovery conditions appropriate to this test. with IS: 9000 severity. The for two hours. and exposed to 16.2.3.2 After recovery the connectors shall be visually examined. There shall be no'visible damage. If specified, the sea!ing test shall be If specified, carried out during the cold test, while at low temperature. the withdrawal force and insertion force test shall be carried out during the cold test, while at low temperature. 162.4 Low Air Pressure 16.2.4.1 This test shall be carried out in accordance with IS : 9000 The duration ( Part 13 )-198 I * using the appropriate degree of severity. of the test shall be five minutes. 16.2.4.2 During the test, a voltage shall be applied between any contact and all othei contacts and the outer metal-parts of the connector connected together. The value of the test voltage shall be specified in During and after this test, there shall the relevant detail specification. breakdown, flashover or harmful be no sign of glow discharge, deformation of the connector. 16.2.5 Damp Heat Accelerated 16.251 ( Remaining Cycle ) This test shall be carried out in accordance with IS : 9000 ( Part 5/S& 2 )-1981*. The connectors shall be subjected to this test for the remaining number of cycles. *Basic environmental testing procedures for electronic and electrical items: Part 2 Cold test, Section 2 Cold test for non-heat dissipating items with gredual change of temperature. Part 5 Damp ht:nt (cyclic I t.zst, Section 2 12 -I- 12 h cycles. Part 13 Low air pressure test. 31 i S : 9647 - 1986 16.2.5.2 The connectors shall then be removed from the chamber and exposed to the standard recovery conditions appropriate to this test or as specified in khe relevant detail specification. After recovery, the connectors shall then be subjected to the following tests and shall meet the requirements specified in rhe relevant detail specification: a) Visual examination, b) Voltage proof, c) Insulation resistance, d) Contact resistance, e) Screen continuity, 0 Insertion and withdrawal force, d h) 3 Bond strength assembly test, Effectiveness of clamping device against cable pulling, and Sealing. three tests shall be carried out immediately following NOTE 1 - The first recovery period. connectors shall not be disturbed prior to the first NOTE 2 - The mated measurement of contact resistance after exposure. The unmated tested sets of connectors shall be mated and unmated three times and then mated again to be measured. 16.3 Damp Heat ( Long-Term Exposure ) 16.3.1 This test shall be carried out in accordance ( Part 4 )-1979" using the appropriate degree of severity. 16.3.2 During conditioning, mated sets between: a polarizing voltage with IS : 9000 to shall be applied a) two adjacent contacts having minimum spacing; and b) all remaining contacts connected together and the shell, or for types having no metallic shell, between the contacts connected together and the mounting plate. The positive potential shall be applied to the contacts. 16.3.2.1 The value of the polarizing voltage shall be 15 V dc, unless otherwise specified. *Basic environmental testing procedures Part 4 Damp heat ( steady state ). for electronic and electrical_[items: 32 IS:9647-1986 16.3.3 The connectors shall then be removed from the chamber and exposed to the standard recovery conditions appropriate to this test or as specified in the relevant detail specification. 16.3.4 The connectors shall then be subjected to the following tests and shall meet the requirements specified in the relevant detail specifications: a) Visual examination; b) 4 d) 4 f) Voltage proof; Insulation resistance; Contact resistance; Insertion and withdrawal Screen continuity; Sealing. and force; d NOTE 1 - recovery The first three tests shall be carried period. out immediately following the NOTE 2 - The mated connectors shall not be disturbed prior to the first measurement of contact resistance after exposure. The unmated tested sets connectors shall be mated and unmated three times, and then be mated again to be measured. 16.4Rapid Change of Temperature 16.4.1 This test shall be carried out in accordance with IS: 9000 ( Part 14/Set 1 )-1978*. The period of exposures to both high and low temperature shall be one hour each. The total number of cycles shall be five. The connectors shall then be removed from the chamber and exposed to the standard recovery conditions appropriate to this test. 16.4.2 The connectors shall then be subjected to the following tests and shall meet the requirements specified in the relevant detail specification: a> Visual examination; b) Voltage proof; c) d) e) f> *Basic Insulation resistance; Contact resistance; Screen continuity; and Sealing. environmental testing procedures for of temperature, Section 1 Rapid method. Part 14 Change chamber electronic and electrical items: change of temperature by two 33 1$:%47-l9$6 16.5 Sealing ( for Sealed"Typts Only. ) 163.1 Nature of Sealing - The following shall be distinguished: 1) Sealing against falling or splashing water; and 2) Sealing against immersion. b) Gas-tightness - The following shall be distinguished: 1) Normal sealing ( rate of leakage of the order of cm3 per hour ); and 2) Hermetic sealing ( rate of leakage of the order of mm3 per hour or less ); Gas tightness only applies to fixed connectors ( connectors themselves and: their mountings ). The severity of the test is given by the allowable rate of leakage specified by the relevant detail specification. a) Liquid-tightness 16.5.2 Region of Sealing - The following shall be distinguished: a) Sealing of unmated connectors, including the sealing of the path of the contact through the insulation and along the length of the joint of insulation and housing; b) Sealing of the mounting of a fixed connector on a panel; c) Sealing of the coupling of a set of connectors; and d) Sealing of the cable entry with appropriate cable in position, 16.5.3 General, - The sealing characteristics ( nature and region of sealing ). are indicated in Table 1; for each type the relevant detail specification shall indicate the characteristic(s) which are required to be determined. Where the region to be measured is a cable entry, the cable shall, be'in accordance with the cable requirements of the relevant detail sgeaification. The paeta, which are not tested, shall; be- protected in such a way that any leakage of those parts has no influence on the accuracy of the measurement. TABLE 1 SEALING NATURE (2) Body Mounting CHARACTERISTICS FALLINGWA~R~ IMMERSION (3) Front-war Front-rear Ftont-xeak Btieriofiintetior Exterior interior REGION (1) Fixed connector Free connector GAS-TIGHTNESS (4) Front-rear Rear-front Front-rear Rear-front Exterior-interior Coupling. of a set ofi conlaactor~ Cable entry 34 IS:~9643- 1986 16.5.4 FaZZing Water - The connectors shall be placed on a horizontal plate at a distance of 80 cm below the water container. The position of the connectors shall be so chosen as to allow the falling water to The duration of impingeon all parts of the surface of the connectors. tfie conditioning is 10 minutes. The outer sur;face of the connectors Pressurized air shall not be shall be and cleaned dried. used and the connects shall not be disengaged'. Within 30 minutes of the end of the conditioning the insulation resistance shall be measured, without the connectors being disengaged. The connectors shalQ then be disengaged and be visually inspected to verify whether water has penetrated into the connectors. The value of the insulation resistance shall be not less than the value specified by the relevant detail specification. No water shall have penetrated into the connectors. 16.55 lrmmersion in Water - This test shall be carried out in accordanae with IS : 2106 ( Part 10 )-l965*. The duration of the conditioning is 48 hours. The outer surface of the connectors shall be cleaned and dried. Pressurized air shall not be used and, the connectors shall not be disengaged. Within 30 minutes of the end of the conditioning the insulation resistafice shall be measured, without the connectors being disengaged. The oonnectors shall, then be disengaged and visually inspected to verify wh&er water has penetrated into the connectors. The value of the insulation resistanoe shall be not less than the value specified by the No water shall1 have penetrate&into the relevant d&ail specification. connectors. 16.5.6 Gas-t.ightness - This test shall be carried out in. accordance with IS : 2106 ( Part 15 )-1966f. of very low rates of leakage ( hermetic NOTE - For the measurement gases other than air may be used. sealing ), Preferred values for the upper limit of the rate of leakage or normal sealing to be quoted by the relevant detail specification are 1 ems/h, S om*/h or 25 cms,`h. arrangements shall be immersed in the fluids specified below for the required period: a) Hydraulic fluid petroleum base aircraft missile and ordnance ( for 20 hours ), and b) Eubricatiag hours 1. immersion rsstL 16.6; Resistanoe C ContamiarPtingVFM& 16.6.1 Unmated connectors of different sizes and oil aircraffi turbine engine synthetic base ( for 20 *Environmental tests for electronic and electrical equipmeat: part 10 Water fEnvironmenta1 tests for electronic and electrical kquip-menr: part' l~7 Gas tightness test. 35 IS : 9647 - 1986 At least one connector shall be immersed in each fluid. The properties of immersion fluids are given in Appendix D. After removal from the fluid, each connector shall remain for one hour in free air at room temperature. The connector items shall then be engaged with their mating parts and assembled connectors shall withstand the voltage specified for a period of 5 minutes chosen from the values of immersion test voltage [ vat ( rms ) 1, that is, 40 V, 1 000 V, 1 400 V, 1 750 V, 2 250 V and 3 500 V. The connectors shall withstand the applied voltage without any breakdown or flashover. 16.7 Attitude Immersion - Mated connectors shall be immersed in a container of water at approximately 20°C and placed in a chamber. Wire ends, opposite the connector, shall be terminated within the altitude chamber, exposed to the chamber atmosphere but not submerged. The exposed wire ends shall not be sealed. A quantity of salt, 5 percent by The chamber weight, shall be added to make the water conductive. pressure shall be reduced to approximately 3'38 kPa and maintained for 30 minutes. The chamber pressure shall then be returned to atmospheric pressure in not more than one minute. While the connectors are still submerged, insulation resistance measurements shall be made, and the requirements of insulation resistance specified shall be met. This shall constitute one cycle. Two additional environmental cycles shall be run. At the end of the third cycle, the insulation resistance measurements made at the end of the first cycle shall be repeated, and the requirements of insulation resistance shall be met. A proof voltage of 1 500 V ac shall be applied between the same points as those used for insulation resistance measurements. The voltage shall be applied while the connectors are still submerged, and at atmospheric pressure. Requirements shall be as given in the relevant detail specification. 16.8 Mould Growth X6.8.1 This test shall be carried out in accordance with IS : 9000 ( Part 10) - 1979*. The duration of exposure shall be 28 days. 16.8.2 After the expiry of the specified period of exposure, there shall be no mould growth on the connectors visible to the naked eye. 16.9 Salt Mist 16.9.1 This test shall be carried ( Part 11 >- 1983* and the severity specification. *Basic environmental Part 10 Mould growth Part 11 Salt mist test. testing test. procedures out in accordance with IS : 9000 specified in the relevant detail for electronic and electrical items: 36 IS : 9647 - 1986 The connectors shall be divided into two groups of mating sets. For the conditioning cycles and for the subsequent recovery periods one group shall be mated and the other unmated. For sealed connectors, the back portion of the fixed items and the free ends of the cable shall be suitably protected to prevent the ingress of moisture. 16.9.2 All the connectors shall then be rinsed in running water not warmer than 38°C with light brushing using a soft hair brush or plastic bristle brush to remover the salt deposits. The surplus water shall be removed by shaking or as specified by the relevant detail specification. 16.9.3 The connectors shall then remain under recovery conditions for a period of 1 to 2 hours, unless otherwise specified by the relevant detail specification. The connectors shall then be subjected to the following tests and shall meet the requirements specified in the relevant detail specification: 4 Visual examination, b) Insertion and withdrawal force, 4 Voltage proof ( high voltage ), d) Insulation resistance, d Contact resistance, f 1 Screen continuity, and 8) Sealing. 16.10 Dust 16.10.1 This test shall be carried out in accordance with IS : 9000 ( Part 12 )-1981 *. The duration of exposure shall be 30 minutes. 16.10.2 After exposure, the connectors shall then be subjected to the following tests and shall meet the requirements specified in the relevant detail specification: a) Visual examination, b) Insertion and withdrawal force, and c) Contact resistance. 16.11 Ozone Exposure 16.11.1 The unmated connectors shall be subjected to ozone having a concentration of 0'010 to 0'015 percent by volume for 2 hours at room *Basic environmental testing procedures for electronic and electrical items: Part 12 Dust test. 37 IS : 9647 - ,1986 temperature. At the end of the specified period, the samples shall be examined for signs of ozone deterioration. !16.11.2 The connectors shall evidence no cracking of materials or other damage, that will adversely affect subsequent performance of the connectors. 16.12 Fire Proofness ( For Fire Proof Connectors ) 16.12.1 The mated, torqued and wired connector shall be mounted on a fixture as shown in Fig. 7. The plug wire bundle shall be wrapped with glass tape or protected by suitable means to ensure that the wire bundle is capable of meeting the electrical requirements of this test. The connector assembly shall be subjected to a 1 093°C Min, flame ( measured 6.35 mm from the assembly for a period of 20 minutes. The flame shall be directed at and envelope the connector plug assembly. The input to the burner shall be natural gas at a flow rate equivalent to an input of 9 673'3 W ( J/s ) during the entire duration of the test. Simultaneously the assembly shall be vibrated continuously at 35 Hz with a total FIG. 7 FIRE-PROOFNESS TESTSET UP 38 a&% :~9647 - 1986 excursionof 6'35 mm. During the first five minutes of the test, all contacts shall carry the dc current specified below. During the sixth minutes of the test, 100 to 125 Vat at 50 Hz shall be applied between adjacent contacts and between contacts and shell. Contact ~~_~~~~h~_~~_~ Size Amperes dc Mating End 22 16 12 41 8 73 48 4 135 0 0 245 16.12.2 Mated connectors shall prevent passing on a flame through the connector for a period of at least 20 minute. During this period there shall be no flame from outgassing or other causes on the end of the connector protected by the firewall. During the sixth minute the connector shall draw not more than 2 amperes when a test potential of loo-125 Vat at 50 HZ is applied between adjacent contacts, and between contacts and the shell. 16.13 Flammability - This test shall be conducted according to Appendix E. 17. MECHANICAL ENDURANCE TEST 17.1 The connectors shall be subjected to a mechanical endurance test in accordance with the relevant detail specification. The mechanical endurance test may be divided into two parts, separated by other tests. 17.2 For this test, the connectors shall be engaged and disengaged with an appropriate mating component. This is considered to be one operation. Locking devices, where fitted, shall be tested separately; thus there will be two series of tests, namely, one for the contacts and one for the locking device. 17.3 The number of operations shall be 500, unless otherwise specified. The relevant detail specification shall specify the frequency of the operations and the minimum time allowed to elapse between successive operatons. 17.4 The connectors shall then be subjected -to the following tests and shall meet the requirements specified in the relevant detail specification: a) Voltage proof, b) Insulation resistance, 39 Wire Barrel End 16 12 IS : 9647 - 1986 c) d) e) f) g) h) Contact resistance, Variation of contact resistance, Screen continuity, Sealing, Insertion and withdrawal force, and Visual examination. ENDURANCE TEST test for 18, ELECTRICAL 18.1 The connectors shall be subjected to an electrical endurance which they shall be mounted as specified in 8.6. 18.2 Each contact of the connector shall be loaded with its rated current. The test shall be carried out at the maximum category temperature and the duration of the test shall be 1 000 hours, unless otherwise specified. 18.2.1 After 25, 100 and 1 000 hours, the insulation resistance at the high temperature shall be measured and shall be not less than the value specified in the relevant detail specification. 18.3 At the end of the 1 000 hour period, the connectors shall be allowed to cool under standard atmospheric conditions for testing. 18.4 The connectors shall then be subjected to the following tests and shall meet the requirements specified in the relevant detail specification: a) Visual examination, b) Voltage proof, c) Insulation resistance, d) Contact resistance, e) Screen continuity, and f) Sealing. 19. ELECTROMAGNETIC INTERFERENCE ( EM1 ) AND RADIO FREQUENCY INTERFERENCE ( RF1 ) SHIELDlNG 19.1 The electromagnetic susceptibility of mated pairs of shells shall be measured in a triaxial radio frequency leakage tester. The RF leakage from the coaxial line through the shells of the connector pairs into the other coaxial geomertry shall be measured at the frequency shown in Table 2 ( accuracy of frequency f 5 percent ). The level of detected signal power indicated by a tuned radio frequency field intensity meter is a result of RF radio frequency leakage from the mated pair ofshells. The test arragements is shown in Fig. 8 and Fig. 9. 40 IS : 9647 FINGER STOCK PROVIDING COMPLETE CIRCUMFERENTIAL COUPLING RING MATED SHELLS SHORT OUTER IOUTER CONDUCTOR COAXIAL LINE CONNECTOR UNDER TEST 1986 ADAPTER -f RFI GASKETS OUTER (INNER RF1 CONOUCTOR COAXl4L LINE1 1 GASKE?S NOTE -The mated pairs of connector shells shall be connected to the centre coaxial line as shown in Fig. 8 and tested as shown in Fig. 9. Attachment of the connector shells to the outer conductor of the inner coaxial line shall be accomplished using RF gaskets to prevent leakage through the adopters. Tests, design requirements and terminations: lines comprising the leakage a) The characteristic impedances of the coaxial tester shall be a nominal 50 ohms. pairs of section. connector shells are removed and b) The SWR (Za-50 ohLms ) looking into B shall be 1.5 or less when the mated replaced by a 50 ohms line the cl The outer coaxial line must not support higher order modes, especially transverse electric (TE) mode, at frequencies below 1 400 MHz. The input and output SWR of the standard be less than 1.5 in the 20 to 100 dB attenuation attenuator range. d: e) ( see Fig. 9 ) should The output impedance of the signal source and the input impedance of the detector ( see Fig. 9 ) shall be nominal 50 ohms having a maximum allowable VSWR of 1.5. Connectors A, B, C, D, E and F ( see Fig. 9 ) should be of a low leakage type which exhibit RF leakage attenuation of 100 dB. FIG. 8 TRI-AXIAL RF 41 LEAKAGE TESTER IS : 9647 - 1986 RF GENERATOR PAD [TYPICALLY RF 10 dB) LEAKAGE TESTER TUNED RADIO FREQUENCY FIE INTENSITY METE SIGNAL SOURCE SECTION DETECTOR SECTION f NOTE - A standard attenuator capable of providing at least 100 dB ( accuracy 3 dB ) of attenuation in one dB step shall be used to measure the RF leakage. to the generator signal frequency by connecting C to A approximately 85 dB attenuation in the standard attenuator. Tune the detector a> and F to E, using (b Disconnect C from A and F from E and couple A to B and D to E. Adjust frequency slightly, if necessary, to maximize output indication on the tuned Record output level. Radio Field Intensity Meter: Disconnect A from B and D from E. Connect C to A and F to E within one minute so as to prevent excessive drift of voltage in the signal source and of calibration in the Tuned Radio Frequency Field Intensity Meter. Adjust the standard attenuator until the output level recorded in step (b) is reached. The value of the attenuation provided by the standard attenuator is a measure of the RF leakage attenuation of the mated pair of shells measured in dB of power. cl FIG. 9 TEST SET-UP FOR TRI-AXIAL RF LEAKAGE TEST 19.1.1 The shells shall exhibit a radio frequency leakage attenuation equal to or greater than that specified in the Table 2. 19.2 She11 to Shell Continuity - The dc resistance of the wired, mated, assembled connectors shall be measured between the points shown in Fig. 10. The applied potential shall be 1'5 volts dc maximum. The resistance shall be inserted in the circuit to limit the current to 0'100 -/0'01 amperes. Probes with spherical ends of 1'27 mm minimum shall be used to make the voltage measurements and shall be placed on the simulated panel at the extreme edge of the plug as shown in Fig. 10,. The probe shall not puncture or otherwise damage the connector. 42 IS : 9647 - 1986 FIG. 10 TABLE 2 SHELL TO SHELL CONTINUITY TEST RADlO DIAGRAM FREQUENCY AND LEAKAGE ATTENUATION ( CIuuse 19.1.1 ) LEAKAGE FREQUENCY ATTENUATION dB MHz (11 100 150 200 300 400 600 800 1 000 (2) 65 2: 55 5; 4": 19.2.1 The dc resistance shall not exceed 0'005 ohms. CONTACTS 20. TEST FOR CRIMPED 20.1 Dimensions ( Before Crimping ) - The contacts for test shall be measured before crimping takes place and the dimensions shall comply with those specified by the relevant specification. Each contact shall then be crimped, using an appropriate crimping pool, to a wire of the dimension as specified in the relevant detail specification. 20.2 Visual Examination ( After Crimping ) - Each contact and crimped connection shall be examined thoroughly using a device having a magnification power of approximately three times. The workmanship 43 IS : 9647 - 1986 and finish shall be satisfactory. Evidence of peeling or chipping of the plating or finish constitutes a failure. The crimped connections shall be inspected and there shall be: a) correct combination of b) freedom from fracture, c) correct insertion of the including the inspection 20.3 Crimp Deformation 20.3.1 Test equipment shall be as follows: a) Axial deformation: 1) Ground precision chuck; 2) Dial gauge indicator; and 3) Stand ( for holding chuck and indicator b) Calibration Requirements: conductor and contact sizes; rougb and sharp edges; and ccnductor in the contact as far as and hole. in proper positicn ). Runout of chuck shall be less than 0'012 3 mm when measured on a steel gauge pin ( approximately 1'587 mm dia >, 25'4 mm away from the chuck face. c) Crimp Barrel Deformation I) Micrometer - standard or dial type, 0'025 mm division. Contacts shall be checked initially to determine conformance Sample shall consist of a contact to the applicable drawings. and conductor crimped together with the specified tool. 20.3.2 Test Procedure 4 Chuck contact on the diameter of the pin or socket contact area immediately preceding the shoulder of the crimp area. b) Position the dial indicator 0'8 mm from the end of the wire entrance end of the contact perpendicular to the centre line of the contact. the maximum and minimum values obtained; this is the total indicator reading ( TIR ). d) Measure maximum diameter of crimp area. The test shall be performed on at least 40 contact pairs, so selected that 20 pairs having the maximum wire size and 20 pairs having the minimum wire size are tested. 20.3.3 Deformation of Crimped Barrel - The out of roundness shall not exceed the maximum diameter of the barrel by more than the amount specified in the relevant detail specification. 44 cl Turn the chuck through 360°C and record the difference between IS : 9647 - 1986. 20.3.4 Axial Deformation - The axial bending of the contacts, due to the crimping operation, shall be measured and shall not exceed the value specified in the relevant detail specification. 20.4 Potential Drop 20.4.1 Light Current - A current of not more than 10 mA supplied by an emf not exceeding 20 mV dc or ac having a frequency of the order of 1 kHz shall be passed through the contacts via the conductor joined to them. The potential drop shall be measured at the points shown in Fig. 11 and shall be not greater than that specified in the relevant detail specification. VOLTMETER PROBES I I l omf e i I SOURCE FIG. 11 POTENTIALDROP MEASURING CIRCUIT ( LENGTH OF LEADS AS SPECIFIED ON RELEVANT DETAIL SPECIPICATION ) 20.4.2 Heavy Current - The test current as specified in the relevant specification supplied by an emf not exceeding the value specified in the relevant specification shall be passed through the mated contacts via the conductors joined to them. The potential drop shall be measured across the wired mated contacts and shall include both crimped joints as shown in Fig. 11. The contacts shall be engaged to the minimum depth experienced in the mated service condition as specified. Measurement shall be taken after the current has been passed for 1 min. The potential drop shall be not greater than that specified in the relevant detail specification. 20.5 Gauge Retention Force ( Resilient Socket Contacts ) - This test shall be carried out according to 13.2. 45 IS : 9647 - 1986 20.6 Resiliency of Individual Socket Contacts 20.6.1 A test pin shall be inserted in the contact while the axis of the contact is in a horizontal position. The test pin shall be mounted on a weighted deviced in such a way that a moment is applied to the contact. With the device free and unsupported, the contacts shall be rotated through 360" in one direction only about their horizontal axes. This procedure is then repeated with the pin inserted for l/2 and 314 of the depth of the first test. X6.2 After this procedure, the socket contact shall pass the requirements for withdrawal force as given in 14.1. 20.6.3 An example of the testing device is illustrated in Fig. 12. CONTACT UNDERA TEST FIG. 12 TESTING DEVICES FOR RESILIENCY OFINDIVIDUAL SOCKET CONTACTS 20.7 Tensile Strength - Each contact shall be placed in a suitable tensile testing machine and an axial pull applied to the wire crimped to it. The jaws of the, machine shall be separated at a steady rate of 2'5 cm to 5 cm per minute. The wire shall not pull out of the contact or break or become distorted to such an extent that it is unfit for use before the minimum tensile strength specified in the relevant detail specification is reached. 20.8 Temperature Cycling Loaded - The contacts shall be connected in series and placed in a suitable lagged chamber set to the temperature specified in the relevant detail specification. The appropriate test current shall be applied through the contacts for one hour. After this period, the current shall be switched off and the contacts removed from the chamber and allowed to cool to standard atmospheric conditions according to IS : 9000 ( Part 1 )-1977*. Accelerated cooling is permissible. This sequence shall be considered to be one cycle, subjected to the *Basic environmental Part 1 General. -testing procedures for electronic and electrical items: 46 IS : 9647- 1986 following tests after all cycles specified in the relevant detail specification have been performed: a) Potential drop-light current, current, and b) Potential drop-heavy c) Tensile strength. 20.9 Corrosive Atmospheric ( Industrial ) 20.9.1 Unmated contacts shall be placed on a non-corrosive rack in a closed plastic or glass chamber ( volume 0'054 cubic meter maximum ) which contains 10 percent solution of potassium sulphide ( KS ) in distilled water. Contacts shall not be immersed in the solution but shall be exposed to the sulphide vapour for 180 hours. 20.9.2 The connectors shall then be subjected and shall meet the requirements specified specification: a) Visual examination, b) Insertion and withdrawal c) Contact resistance. force, and to the following tests in the relevant detail 20.10 Contact Strength - With the pin contacts mounted in a suitable fixture, a load shall be applied to the contact as shown in the relevant detail specification. The load shall be applied steadily until the load specified has been reached; this load shall be applied for 1 min. The permanent set of the pin shall be measured immediately after load removal. This `set' shall be considered to be the difference between the initia1 and the final position of the contact stip as shown in the relevant detail specification. APPENDIX ( Clause 11.1 ) A GUIDE ON CLEARANCES AND CREEPAGE DISTANCE A-l. The maximum test voltage which may be allowed clearance or a creepage distance are shown in Table 3. 47 on a given IS:9647 - 1986 TABLE 3 MAXIMUM TEST VOLTAGES ( Clause A-l ) TEST VOLTAGE ( PEAK ) 700 1 400 1 700 2 300 2 700 2 800 3 200 3 500 3900 4 360 4 700 5 100 5 300 5 700 6 100 6 500 7 100 7 900 8 700 9 700 CLEARANCE mm 0.5 CREEPAGEDISTANCE mm 0.5 1 2 2.5 2.5 3 3.5 4 6" 7 8 1: i.5 11 :: 1'5" if 14 10 700 NOTE 1 noted that: When the requirements 15 16 17.5 it should be directly to of IS : 616-1981* are applicable, pass connected a) the minimum the mains; b) the minimum test voltages ( peak ); and c) the clearance parts or earth test voltage is 2 800 V ( peak ) for clearance and the minimum creepage distance are 2 mm for up to 700 V ( peak ) and 3 mm for test voltages up to 2 800 V and the creepage distance between any contact connections shall be not less than 4 mm. and outer meta values of either voltage or distance the most NOTE 2 - For intermediate appropriate values from the safety aspect must be chosen from the table. NOTE 3 - For test voltages trodes has such an influence distances may be given. exceeding 12 000 V ( peak) the form of the electhat no general rules for clearance and creepage NOTE 4 - If an insulating part contains a groove of less than 1 mm [ for test voltages equal to or less than 700 V ( peak ) 0.5 mm ] width, the creepage distance shall not be measured over the surface of the groove but only across its width. If a clearance consists of two or more air gaps in series any gap of less than 1 mm [ for test voltages equal to or less than 700 V ( peak ) - 0.5 mm ] width is ignored in computing the total distance. *Safety requirement for mains operated electronic household and similar general use (first revision). 48 and related apparatus for IS : 9647- 1986 A-l.1 For application at high altitudes and/or high temperature the voltage specified in Table 3 shall be derated by dividing the calculated rated voltage by the factors given in Tables 4 and 5. TABLE 4 RECOMMENDED VOLTAGE ) DIVIDINQ FACTOR DERATING FACTORS FOR ALTITUDE ( Clause A-l.1 ALTITUDE, m `From Up to and Including 2 000 3 000 4000 5 000 6 000 7 000 8 000 9 000 10 000 ' 2 000 3 000 4 000 5 000 6 000 7000 8 000 9 000 PRESSURE.mbar r___---T Down to From and Including 795 795 700 700 620 620 540 540 470 470 410 410 355 355 305 305 565 1 1'35 I.5 1.65 1.95 2.25 2.65 3 3.3 TABEE 5 RECOMMENDED VOLTAGE FACTORS FOR TEMPERATURE ( Clause A-l.1 ) DERATING TEMpfYE DIVIDING FACTOR 1 1.03 1.07 1.1 1.14 1'17 1.21 1.24 1-28 - 20 30 40 50 60 70 80 90 100 49 IS : 9647 - 1986 APPENDIX B ( Chuse 12.1.6 ) TYPICAL EXAMPLES OF METHODS OF MEASUREMENT B-l. DRY CIRCUIT B-l.1 The dry circuit test procedure shall be as follows. The electronic galvanometer used in these tests shall have a minimum impedance of 10 000 ohms. a) Microvolt Range - Dry circuit tests shall be made using the circuit shown in Fig. 13. Apply 0'1 microvolt dc across the test specimens and with the polarity of the source voltage reversed. No voltage greater than 0'1 microvolt shall be applied to the test specimens prior to the application of the test voltage. Electrical continuity, current flow in both directions with the reversal of polarity of the source voltage with the knife switch, as indicated by the Keithelev 150 A or equivalent microvolt ammeter in series with the test specimens, shall be evidence of satisfactory compliance. No measurement of voltage drop across the test item is required. VOLTAGE DIVIDER No.1 DIVIDER No.2 VOLTAGE DOUBLE POLE, 3 POSITION CENTRE OFF,KNIFE SWITCH ST SPECIMEN (TE!J CONTACTS IN SERIES) L FOR OPEN CIRCUIT CALIBRATION ONLY, REMOVE FOR TEST FIG. 13 MICROVOLT CIRCUIT b) MilZivoZt Range - Tests shall be conducted using the circuits shown in Fig. 14. The output of the power source shall be adjusted to give an open circuit voltage of 20 millivolts dc across the 3 ampere, 50 millivolt shunt and this voltage shall be impress< ed across the test circuit in order to determine the contact 50 IS : 9641- 1986 DOUBLE CENTRE POLE 3 POSiTION OFF KNITE SWITCH r--- (lo/ MILLIMETER ACCURACY ) \3A 50mV SHUNT TEST. SPECIMEN \ (TEN C;"ETA:":: IN FIG. 14 MILLIVOLT CIRCUIT resistance of specimens. The resistance of the one ohm variable series resistor in thecircuit shall be adjusted to limit the current through the test specimen to a value between 10 and 50 milliamperes. A careful measurement of voltage drop across the test specimens and the current through them will yield the parameters necessary to determine contact resistance. The one ohm variable resistor or when necessary, the impressed voltage shall then be adjusted to increase the current to 2+ times that initially obtained and the contact resistance re-determined. These values of contact resistance shall be not greater than specified. B-l.2 The mated `pair of connectors shall show no electrical discontinuity and the contact resistance shall be as specified. B-2. LOW LEVEL CIRCUIT B-2.1 The low level circuit shown in Fig. 15 shall be used that will deliver 1 mA current when the variable resistor is adjusted to provide a 20 mV open circuit potential between T1 and T2. The mated test items shall be mounted rigidly to the fixture to provide mechanical stability. Direct current shall be used for measurement in the forward and reverse direction. Potential drop shall be measured by formula $ = R, the higher of the two resistance values shall not exceed the required values. If total resistance between r1 and T2 exceeds 0'1 ohms ( 0'1 m V drop ) then the total number of contacts in series shall be reduced for accurate readings. B-2.2 Conditioning - Two wires shall be terminated on each contact. 51 IS : 9647 - 1986 r MILLIAMMETER (+ lo/. ACCURACY) MICROVOLTMETER CSNTRE 3 POSITION KNIFE SWITCH (NECESSARY ONLY DC SOURCE ) 15A OFF, FOR SAMPLE CURRENT MEASURING RESISTOR (*lo/. ACCURACY) LOW LEVEL CIRCUIT 2 L VOLTAGE-DROP POINTS `1 CONNECTIONS POTTING 0~ 15B MEASUREMENT V,,V2,V3,ETC. SHALL 8 SHALL EOUIPM.ENT TYPICAL CONNECTION BE PERMANENl BY BE PROTECTED MEANS DIAGRAM WIRING FIG. 15 Low LEVEL CIRCUIT AND TYPICAL WIRING DIAGRAM The connectors shall be mated with the printed circuit board. One of the wires shall provide a series ( current lead ) circuit between contacts and the second wire shall provide an individual contact resistanci measuring point ( voltage lead ). For test points see relevant detail specification. 52 IS :9647- 1984 B-2.3 Precautions a) Terminal voltage shall never exceed 20 mV dc, b) The 3 position switch shown shall be opened before each contact resistance measurement to zero the voltmeter, c) The total resistance of the current leads shall be less than 100, milliohms ( including test contacts and current monitoring resistor ), and d) Voltage drop measurement connection points shall be permanent connections and may be protected by potting or equivalent means. B-2.4 The resistance of any contact shall not exceed seven milliohms. APPENDIX C ( Clause 14.3.2 ) TYPICAL EXAMPLE OF TEST C-l. The socket connector shall be mounted as `in normal service tora rigid panel. Before mating the plug connector to the socket, the J adapter or test torque arm shall be attached as shown in Fig. 16. After mating the plug and socket connectors, the distance L from the point of load application P to the mounting panel shall be determined. The load to be applied at point P shall then be determined as the bending SIMULATED rSOCKET MOUNTING CONNECTOR IEO P PANEL FIG. 16 EXTERNAL BENDING MOMENTTEST SET UP w ARM LJ ADAPTER \-PLUG CONNECTOR 53 IS :9647 - 1986 moment listed in Table 6 divided by the level arm L. This load shall be applied at a rate of approximately 45 N per second until the required load is achieved. The load so applied shall be held for a period of one minute after which load shall be released. Continuity of the contacts shall be monitored, during the test. The connector shall be removed, unmated, and inspected to 3 times magnification for damage or breakage. TABLE 6 PLUG SHELL SIZE AND BENDING ( Clause C-l > PLUG SHELL SIZE 18 20 22 24 MOMENT BENDING MOMENT Nm 48.9 51.98 56'5 59.33 PLUGSHELL SIZE 8 10 14 16 -~-s.__cy.-h~I__y BENDING MOMENT Nm 6'66 27 38.95 47.34 C-2. Connectors shall show no evidence of damage any interruption of electrical continuity. nor shall there be APPENDIX PROPERTIES D-l. D FLUIDS ( Clause 16.5.5.1 ) OF IMMERSION FOR ENVIRONMENTAL RESISTANCE ( SOLDER CONTACT AND CRIMP CONTACT) TYPES a) Hydra?rIic Fluid Petroleum Base Aircraft Missile and Ordance Physical properties of finished fluid shall be as follows: Value Properties Viscosity in centistokes at 99°C (Min) Viscosity in centistokes at 37'8°C (Min) Viscosity in centistokes at - 40°C (Max) Viscosity in centistokes at - 54°C (Max) Pour point (Max) Flash point (Min) Acid or base number (Max) 54 1:*00 500'0 3 000'0 - 59'4°C 93'3°C 0'20 IS :9647 - 1986 b) Lubricating Oil Aircraft Turbine Engine Synthetic Base content of the lubricating oil shall be as 1) The trade element follows: Element Aluminium (Al) lron (Fe) Chromium (Cr) Silver (Ag) Copper (Cu) Tin (Sn) Magnesium (Mg) Nickel (Ni) Titanium (Ti) Lead (Pb) Silicon (Si) Content Limit 3 ppm, Max 4 ,, 3 ,, 1 ,, : :: : :: 1 Reiort ,, only 2) The physical and chemical properties of the lubricating shall conform to the requirements given below: Total acid number (Max) Viscosity in centistokes at 98'0" (Min) Viscosity in cectistokes at 37'8" (J4in) Flash point "C (Min) Evaporation percent (Max) Pour point "C (Max) 0'30 0'3 11'0 204 -:50 oil D-2. FOR FIRE PROOF AND HERMETICALLY SEALED TYPES Test Fluids and Tests Procedure shall be as given in Table 7. Test fluids and test procedures The physical properties of lubricating oil aircraft turbine engine synthetic base shall be as follows: Viscosity in centistokes at 98'9°C (Min) 5'00 Viscosity in centistokes at 98'9°C (Max) 5.50 Viscosity in centistokes at 37'8°C (Min) 25'0 Flash point (Min) 246°C Pour point (Max) - 54°C Total acid number (Max) 0'50 55 IS : 9647 - 1986 TABLE 7 TEST FLUlDS AND TEST PROCEDURES SL No. (1) i) ii) TEST FLUID (2) Lubricating oil [ as in D-l (b) ] Lubricating oil [ as in D-2 (b) ] ( Clause D-2 ) TEST PROCEDURE (3) Immerse unmated connectors in fluid at 120 f 3°C for 5 minutes. Remove the connectors and allow to drain for one Fluid shall be derained hour at room temperature. from all recesses. Mate connectors and expose to 175 f 3°C in air circulating over for 22 hours. Repeat procedure for a total of 7 cycles. Same as above, except immerse in fluid at 83 f 3°C for five minutes and expose mated connector to 104 f 3°C in an air circulating oven for 22 hours. Same as in (i) except fluid temperature shall be 650 f 3°C and connector shall be mated during fluid immersion. Same as in (iv). Unmated connectors shall be preconditioned at 175°C for 30 minutes. Immerse connector fully in room temperature fluid for one minute. Remove connectors and allow to stabilize at room temperature for one hour. Same as in (i) except fluid temperature shall be room ambient. Physical and chemical requirements as in D-2 (c). iii) iv) v) vi) Hydraulic fluid [as in D-l (a) ] Glycol ( ethylene glycol ) Alkaline clearing solution pH lo-12 Coolant dielectric fluid synthetic silicate foster base Turbine fuel aviation grade ( JP-5 ) vii) c) The chemical and physical properties grade JP-5 are as given below: Requirements Distillation: of turbine fuel aviation JP-5 Report only 204'4°C Report only Report only Report only 287'8°C 13 I+ 0'845 0'788 :4 0'4 0'001 Initial boiling point Fuel evaporated, 10 percent, Min at Fuel evaporated, 20 percent, Min at Fuel evaporated, 50 percent, Min at Fuel evaporated, 90 percent, Min at End point, Max Residue vol percent, Max Distillation loss vol percent, MUX Gravity "API-Min ( sp gr, Max ) Gravity "API-Max ( sp gr, Min ) Existent gum, mg/lOO ml, Max Total potential residue, 16 hours ageing, mg/lOO ml, Max Sulphur, total percent, weight Mercaptan sulphur, percent by weight, Max 56 IS : 9647 - 1986 Freezing point, Max Requirements Heating Value: - 46°C HP-5 4 255'800 (Min) 16'5 (Max) 25'0 (Max) 5'0 (Max) 19 (Min) 50 (Max) 60°C (Min) Net heat of combustion, kJ/kg Viscosity in centistokes at - 34'4°C Aromatics volume present Olefin volume present Smoke point Explosiveness percent Flash point Smoke volatility index, Min Water separation index modified Change in pressure drop in 5 hours Preheater deposit code less than Perticulate matter mg/litre Total acid number lO'l:\ 85°C (Min) Pa (Max) 106 (Max) 0'015 (Max) APPENDIX ( Clause 16.11 ) FLAMMABILITY E-l. OBJECT E-l.1 The object of this test is to determine support combustion. E-2. TEST CHAMBER E whether components will E-2.1 The chamber shall consist of an enclosure protected from air currents, but provided with means of venting fumes and admitting an adequate supply of fresh air at the bottom. NOTE 1 - A meta box about 600 mm wide, 900 mm high and 600 mm deep with a detachable front, a viewing window and suitable holes for intake of air and venting of fumes can be used. possible explosion of the components. NOTE 2 - Adequate safety precuations shall be taken to protect personnel from E-2.2 A suitable stand or support for the components involving a minimum of heat transfer shall be used inside the chamber. 57 IS-: 9647 - 1986 E-2.3 A spirit burner of the pattern shown in Fig. 17 shall be used. The fuel for the burner shall be good quality 66 0. P. industrial methylated spirit containing not more than 5 percent of wood naptha. The burner and the flame are considered satisfactory if a bare copper wire 0'71 mm dia having a free length of not less than 100 mm in the flame in the position to be occupied by the ccmponents, melts in less than 6 seconds. NOTE The melting point of copper is 1 083°C. OF COMPONENTS E-3. MOUNTING E-3.1 The components shall be mounted on the stand placed within the test chamber so that they are not shielded from the flame by the support. The precise orientation of the components relative to the flame, if not stated in the relevant component specification, shall be that judged to be the most unfavourable or which presents maximum surface to the test flame. The height of the components shall be so adjusted that the lowest part of the body of the component is 51'00 & 1 mm from the top of ihe burner as shown in Fig. 18. E-4. TESTING E-4.1 After confirming that the flame the hurrier shall be placed underneath that they are enveloped by the flame. to the fiame for it, either 1 minute or ignition. is satisfactory as specified in E-2.3, the components in such a manner The components shall be exposed any lesser time necessary to cause E-4.2 If ignition of the components has occurred, it shall not continue for more than. 15 seconds or any other period specified in the relevant component specification, after withdrawal of the flame. E-4.3 The components shall be deemed to have failed if burning particles become detached from thelm. 58